Quilt-stitched internal mattress pillows

ABSTRACT

A mattress has a quilted internal pillow wherein one or more internal layers of material are quilt-stitched prior to encapsulation in mattress upholstery. The quilted internal pillow is positioned relative to a support surface of an innerspring or spring core of a mattress to provide support characteristics determined by the quilt stitch pattern. In a related method of manufacture of a mattress with an internal quilt stitched pillow, the layer or layers of the pillow are processed through a quilter stitching machine and then assembled in combination with a mattress spring core and upholstery. The quilted internal pillow may be located adjacent to the spring core, spaced from the spring core by other internal layers of material, or located adjacent to or within a mattress pillowtop, and in each embodiment on one or both sides of the mattress.

FIELD OF THE INVENTION

[0001] The present invention pertains generally to cushioned andupholstered support structures and, more particularly, to supportstructures which have multiple internal and assembled components.

BACKGROUND OF THE INVENTION

[0002] A typical innerspring mattress includes an innerspring assemblyhaving an array of interconnected coils of helical wire or other type ofreflexive elements, one or more layers of material over the supportsurfaces of the innerspring, one or more layers of polymer foam over thesupport surfaces of the innerspring, and an upholstery layer coveringthese components. In a two-sided mattress, the support surfaces of bothsides of the innerspring are covered with one or more layers of polymerfoams, fiber batting and fabric layers of material such as cotton orwool. The internal layers are then encased in upholstery which istypically a quilted exterior layer, also referred to simply asupholstery or ticking. The seams of the upholstery layer are sewntogether (often with tape edging) about the perimeter of the supportsurfaces. The edge or border of the innerspring between the supportsurfaces is similarly covered with upholstery, the edges of which aresewn to the edges of the support surface covers with a tape edge.

[0003] The upholstery material commonly has a quilted stitch pattern anda foam backing. This quilt stitch pattern is provided either by theupholstery material manufacturer, or in a mattress factory equipped witha quilt stitching machine, such as a Gribetz International, Kaybe, Emcoor Matramatic type automated quilting machine, which have a linear arrayof controllable/programmable sewing needles and is programmable to sewany desired pattern into a swatch of material as it is passed under thearray of needles. The decorative nature of the stitch pattern lendsitself to application on the upholstery layer. However, any type orcombinations of material penetrable by the the needles of the quilterare able to be sewn by such quilting machines. Prior to this invention,few if any applications of quilting machines have been made to thestitching of non-upholstery material layers or to any materialsinstalled in the interior of a mattress.

[0004] Cushioning layers underneath the upholstery, including highdensity foam and man made fiber batts, in combination with other paddedor quilted upholstery layers, can make the mattress very bulky androunded at the edges. As a result, it is difficult to sew together theseams around the periphery of the mattress. This requires expertoperation of a large tape edge stitching machine mounted at an obliqueangle to the mattress. The sewing head must traverse the entireperimeter of the mattress, while keeping the internal layers of materialin alignment. Thus, as the perimeter of the upholstery layer is stitchedby the quilting machine, the cushioning layers within the mattress tendto shift, shifting the dimensions of the mattress as well. This isespecially true of double-sided mattresses, with layers of cushioningmaterial on both sides of the spring assembly. As the mattress layersshift, the dimensions of the mattress are skewed and the finished shapeof the mattress is distorted. A method and construction for maintainingalignment of internal layers of a mattress during and after assembly istherefore desirable.

[0005] Additional objects, advantages and novel features of theinvention will be set forth in part in the description which follows,and in part will become apparent to those skilled in the art uponexamination of the following or may be learned by practice of theinvention. The objects and advantages of the invention may be realizedand attained by various structures as covered by the patent claims.

SUMMARY OF THE PRESENT INVENTION

[0006] The present invention provides a quilted internal mattress pillowwhich enhances dimensional stability of the mattress construction byquilt stitching one or more layers of internal material prior toinstallation or encapsulation by the mattress upholstery. By quiltstitching internal layers together, the alignment of the layers ismaintained during final assembly and thereafter, and the supportcharacteristics of the quilt-stitched internal layers are alteredaccording to the stitch pattern. The quilted internal layer or layers donot shift relatively during stitching of the seams of the upholsterylayer. In another aspect of the invention of quilt-stitching togetherinternal layers of a mattress prior to assembly, the body of the quiltedinternal pillow may also contain a concentration of stitches in thelumbar or other areas to customize the support characteristics of themattress.

[0007] In accordance with one general aspect of the invention, there isprovided a quilted internal pillow which has at least one layer ofsupporting material and at least one layer of backing material quiltedtogether prior to installation in a mattress. In one particularembodiment, the quilt-stitched internal layers are foam layers, and in afurther embodiment one of the internal layers has a thickness or densitygreater than the other internal layer to which is it attached. One ormore of the internal layers may be in the shape of a slab or planarpiece, or have a convoluted surface, illustrating the principle thatmaterial layers of different configurations can be quilt-stitch attachedto other layers by processing through automated quilt stitchingmachinery. Further, the quilting is performed by stitching the internalpillow, wherein the stitches extend through all layers of the quiltedpillow to prevent lateral, longitudinal or sliding movement of thelayers during handling and installation into the mattress.

[0008] The quilt stitching is preferably in a pattern or matrix locatedwithin the perimeter of the layers of the internal pillow, as comparedto an edge or perimeter stitch. However, some of the stitches of thequilt-stitch pattern may be located proximate to the edges of theinternal pillow layers so that the layers are adequately securedthroughout. The quilt-stitching may be more concentrated in selectedareas such as the lumbar area, thus, the higher concentration ofstitching would create more density and support in that specific region.The internal quilted pillow is then inserted into a mattress between theupholstery layer and the spring assembly. The spring assembly includesan innerspring made of a plurality of springs or coils connectedtogether in an array. In the case of a double-sided mattress, a secondquilted internal pillow is inserted on the other side of the springassembly, opposite to the first internal pillow to create a mattresswith symmetrical sides of cushioning.

[0009] In accordance with another aspect of the invention, there isprovided a quilted internal pillow which has at least one layer ofsupporting material and at least one layer of backing material quiltedtogether and then inserted into a mattress. The quilted internal pillowis inserted into the mattress as a part of the pillow top. Theinnerspring is encased in the upholstery layer and stitched together.Thus, the mattress is stitched together by stitching the perimeter seamsof the gusset and the pillow top together.

[0010] In an associated method of mattress manufacture of the presentinvention, a new use for the quilting machine is described. In the priorart, automated quilting machines are used exclusively to quilt-stitchthe exterior upholstery layer of a mattress before it is installed as acover over an innerspring and other materials. The present inventionutilizes the quilting machine for quilt stitching together multiplelayers of an internal mattress pillow, prior to installation of thepillow in a mattress. The quilt stitch patterns which may be used in themanufacture of the internal mattress pillows of the invention can be anyof the patterns producible by the available machinery and controlsystems and software, and functional as attachment or fastening, and toalter the support characteristics of the internal mattress pillow.

[0011] These and other aspects of the present invention are hereindescribed in further detail, with reference to the accompanying Figures,the illustrated embodiments being representative of only some of theyways in which the principles and concepts of the invention can beexecuted and employed.

DESCRIPTION OF THE FIGURES

[0012] In the accompanying Figures:

[0013]FIG. 1 is a perspective peel-away view of an entire mattress,showing the internal pillow quilted together;

[0014]FIG. 2 is a top view of the quilted internal pillow of the presentinvention;

[0015]FIG. 3 is an elevational cross-sectional view of an entiremattress, showing the internal pillow quilted together;

[0016]FIG. 4 is an elevational cross-sectional view of a double-sidedmattress, showing the internal pillow quilted together; and

[0017]FIG. 5 is a perspective view of the quilted internal pillowinserted in the mattress as part of the pillow top, and

[0018]FIG. 6 is a cross-sectional view of a double-sided pillowtopmattress with quilted internal pillows of the present invention.

DETAILED DESCRIPTION OF PREFERRED AND ALTERNATE EMBODIMENTS

[0019] With reference to the Figures, there is shown a mattress 5 whichincludes an internal pillow, generally indicated at 10, which includesin one embodiment at least one layer of material 28 and a second orthird layer of material 30, each of the layers being quilt-stitchedtogether. Although referred to herein as a “pillow”, the internalquilt-stitched layer or layers 10 may be in any particular form, size orshape, the primary physical characteristic being one or more layerswhich are sewn together in a quilt stitch pattern prior to insertion orinclusion in the interior of a mattress, i.e., inside of the upholsteryof the mattress. The central layer of material 28 may be a foam layer,such as slab or convoluted foam, or any other suitable material, butwhich preferably has some compressible thickness or loft, with anappropriate density to function as an internal mattress pillow. Theouter layer or layers 30 of the pillow 10 may be similar to layer 28, oralternatively a fiber batt or other woven or non-woven sheet material.In a single layer embodiment, quilt stitching is placed throughout thearea of the single layer to alter the spatial density and supportcharacteristics of the layer. As used herein, the term quilt stitchingrefers to any stitch pattern which can be made in the internal pillowlayers, as made by the described commercial quilt stitching machines,and which is located within the perimeter of the layer or layers, andwhich is in any pattern within the area of the layer or layers.

[0020] As shown in FIG. 2, quilt stitching 18 is placed throughout theexpanse or surface area of the internal pillow 10, with the stitches 22extending substantially through the cross-section of layers 28 and 30 tothereby stitch and retain them together. As further described, theinternal quilted pillow 10 is quilted prior to insertion into a mattress5 to prevent lateral, longitudinal or sliding movement of the supportingand backing layers 28 and 30 when in contact with the upholstery layer12. Additionally, the quilt stitching 22 in the body 11 of the internalpillow 10 can be used to control the density and support of specificareas of the mattress 5. Stitches 22 can be concentrated in differentareas on the body 11 of the internal pillow 10, depending on the needsof the user. In areas where there is a higher concentration of stitches22, the internal pillow 10 would exhibit more density and support. Forexample, a higher concentration of stitches 22 may be added to thelumbar area to create more density and more support for user's that havechronic sore back muscles. Thus, the amount of stitches 22 quilted intothe body 11 of the internal pillow 10 allows for varying degrees ofdensity and support.

[0021] Once the layers 28 and 30 of the internal pillow 10 arequilt-stitched together, they are inserted into a mattress 5, as shownin FIG. 1. According to one embodiment of the present invention, theinternal pillow 10 is inserted into a mattress 5 between the upholsterylayer 12 and the mattress innerspring 20. The internal pillow 10 isdimensioned to fit upon and substantially cover the support surface areaof the innerspring, which may be any form of an array of interconnectedspring coils 34.

[0022] The innerspring 20 and internal quilted pillow 10 areencapsulated or covered by an outer upholstery cover layer 12, whichextends over the planar support surfaces of the innerspring and aboutthe perimeter or border of the innerspring. The upholstery 12 iscommonly made of a woven fabric material, which is also commonlydecoratively embroidered, and may also have a quilted stitch patternwhich secures a padded backing layer, such as a thin foam layer, to theback side of the upholstery. This type of external upholstery quiltstitch pattern, however, is distinguished from the internal quilt stitchpattern of the internal pillow layers of the present invention.

[0023] Once the internal pillow 10 is properly positioned within themattress 5, the perimeter seams 24 of the upholstery layer 12 are thenstitched together, retaining the internal pillow 10 within the mattress5. The panels and border of the upholstery material 12 are joined at theedges by perimeter seams 24, which may include a surrounding tape edge.The quilt pre-stitching of the layers 28 and 30 of the internal pillow10 before insertion into the mattress 5 provides dimensional stabilityof all the cushioning components, and thereby avoids the manufacturingstep of maintaining alignment even overlay of the internal layers as theupholstery is applied. As the perimeter seams 24 of the upholstery layer12 are stitched together, the quilt stitching of the internal pillow 10retains the layers 28 and 30 in proper positional and planar alignment.Thus, the internal cushioning layers will not shift during assembly ofthe mattress 5.

[0024] As shown in FIG. 4, in a double-sided mattress, a second quiltedinternal pillow 10 can be provided on an opposite side of theinnerspring 20, opposite to the first internal pillow 10. Once thequilted internal pillow(s) 10 are in position, the perimeter seams 24 ofthe upholstery layer 12 are then stitched to retain the internal pillows10 within the mattress 5. The layers 28 and 30 of both internal pillows10 are quilted together prior to insertion in the mattress 5 aspreviously described.

[0025] Referring now to FIGS. 5 and 6, in another embodiment of thepresent invention, the internal pillow 10 is inserted into a mattress 5as an internal component of a mattress pillow top 36. The springassembly 20 is encapsulated by an outer upholstery cover 12 and stitchedtogether. One manner of attachment of the pillow top 36 is by a gusset38 is sewn along the perimeter of the mattress 5, either to a border orto the top of an inner panel which covers the innerspring. The edges ofa top upholstery layer are then sewn to the edges of the gusset. Anothertype of pillow top attachment is to adhesively attach a gusset to theinnerspring covering and to the pillow top covering upholstery. Thequilted internal pillow of the invention can be installed in connectionwith a pillow top in these or other equivalent manners, whereby thequilted internal pillow 10 is an integral internal component of amattress pillow top. As in the first embodiment, the layers 28 and 30 ofthe internal pillow 10 are quilt stitched together prior to installationin the mattress 5.

[0026] As shown in FIG. 6, in a double-sided mattress, a second quiltedinternal pillow 10 can be inserted as a part of the pillow top 36 on theother side of the innerspring 20, opposite to the first internal pillow10. Once the quilted internal pillow(s) 10 are in position, the pillowtops 36 are integrally constructed over or in connection with theinternal pillow 10. The perimeter seams 24 of the gusset 38 and thepillow top 36 are top stitched or surged together to retain the internalpillows 10.

[0027] It will be appreciated by persons skilled in the art thatnumerous variations and/or modifications may be made to the invention asshown in the specific embodiments without departing from the spirit orscope of the invention as broadly described. The present embodimentsare, therefore, to be considered in all respects as illustrative and notrestrictive. Other features and aspects of this invention will beappreciated by those skilled in the art of designing and manufacturingmattresses upon reading and comprehending this disclosure. Suchfeatures, aspects, and expected variations and modifications of thereported results and examples are clearly within the scope of theinvention where the invention is limited solely by the scope of thefollowing claims.

What is claimed as the invention is:
 1. A mattress comprising: aninnerspring; an internal mattress pillow having at least two layers ofmaterial which are in planar contact, with a quilt stitch pattern in amajor expanse of the layers, stitches of the quilt stitch patternextending through the layers to hold the layers together and to maintainalignment of the layers; the internal mattress pillow being encapsulatedwith the innerspring within upholstery material.
 2. The mattress ofclaim 1 wherein the quilted internal pillow comprises three layers, andwherein stitches of the quilt stitch pattern extend through all threelayers.
 3. The mattress of claim 1 wherein the quilted internal pillowis located adjacent to the innerspring.
 4. The mattress of claim 1wherein the internal pillow is inserted into the mattress between anupholstery layer and the innerspring.
 5. The mattress of claim 1 whereinthe internal pillow is retained within the mattress by a perimeter seamof the upholstery layer.
 6. The mattress of claim 1 further comprising asecond internal pillow on an opposite side of the innerspring.
 7. Themattress of claim 1 wherein the layers of material of the internalquilted pillow are foam material.
 8. The mattress of claim 7 wherein atleast one of the layers of the internal quilted pillow has a densitydifferent than another layer.
 9. The mattress of claim 1 wherein thelayers of the internal quilted pillow are generally planar.
 10. Themattress of claim 1 wherein at least one of the layers of the internalquilted pillow has a contoured surface.
 11. The mattress of claim 1wherein the quilted internal pillow is located adjacent to a supportsurface of the mattress covered by an upholstery layer.
 12. The mattressof claim 1 wherein quilt stitches in the quilted internal pillow arevariable in number and placement across the area of the quilted internalpillow.
 13. The mattress of claim 1 wherein the quilted internal pillowis a supporting component of a mattress pillowtop.
 14. The mattress ofclaim 13 wherein the quilted internal pillow is at least partiallyencapsulated by a gusset attached to an upholstery layer.
 15. Themattress of claim 1 further comprising a mattress pillowtop, wherein thequilted internal pillow underlies the mattress pillowtop.
 16. Themattress of claim 15 wherein the quilted internal pillow is retainedwithin the mattress by attachment of a mattress pillowtop to a perimeterof the mattress upholstery.
 17. The mattress of claim 15 furthercomprising a second mattress pillowtop and a second quilted internalpillowtop which underlies the second mattress pillowtop.
 18. Themattress of claim 1 wherein the quilted internal pillow comprises threelayers including a central layer and two outer layers, with the centrallayer having a thickness or density greater than a thickness or densityof at least one of the outer layers.
 19. A mattress comprising: aninnerspring having two parallel planar support surfaces; a quiltedinternal pillow placed to substantially overlie a planar support surfaceof the innerspring, the quilted internal pillow having at least twolayers of material which are attached together by a patterned quiltstitch substantially throughout the area of each layer; the quiltedinternal pillow being quilt stitched together prior to encapsulation inupholstery material about an exterior of the mattress.
 20. The mattressof claim 19 further comprising a second quilted internal pillowpositioned on a side of the innerspring opposite the other quiltedinternal pillow.
 21. The mattress of claim 19 further comprising atleast one additional layer of material between a support surface of theinnerspring and the quilted internal pillow.
 22. The mattress of claim19 wherein the quilted internal pillow is located proximate to apillowtop of the mattress.
 23. A mattress having an innerspring and atleast two internal layers, the innerspring and internal layers beingencapsulated in an upholstery material, at least one of the internallayers being an internal quilted pillow comprised of at least two layersof material which are attached together by a quilt stitch patternthroughout a substantial area of the attached layers, wherein thestitches of the quilt stitch pattern extend through each of the layersof the internal quilted pillow.
 24. A mattress having an innerspring inthe form of an array of spring elements defining first and second planarsupport surfaces, a material layer which substantially covers one of thesupport surfaces of the innerspring, the material layer comprising aquilted internal pillow having at least two layers of material which aresewn together by a quilt stitch pattern within the perimeters of the twolayers, the stitches of the quilt stitch pattern extending through thetwo layers to bind the two layers together, the quilted internal pillowbeing retained in position with respect to the support surface of theinnerspring by an upholstery material which encapsulates the innerspringand the internal quilted pillow.
 25. A mattress having a spring core, atleast one internal layer of flexible material, and an externalupholstery material which encapsulates the spring core and the internallayer, the internal layer comprising an internal quilted pillow havingat least two layers which are generally aligned and attached together bya quilt stitch pattern in a contact area of the two layers.
 26. A methodof manufacturing a mattress having an innerspring and an internalquilted pillow encapsulated by external upholstery material, the methodcomprising the steps of: providing an innerspring which has two planaropposed support surfaces; providing an internal quilted pillowdimensioned to cover a support surface of the innerspring, the quiltedinternal pillow having one or more layers of material with a quiltstitch pattern within a perimeter of the layer, the quilt stitch patternbeing formed in the internal quilted pillow prior to positioningrelative to the support surface of the innerspring and encapsulation ofthe quilted internal pillow within the upholstery material.
 27. Amattress comprising: an innerspring having a flexible core with opposedplanar surfaces to provide first and second support surfaces; aquilt-stitched internal pillow having at least two layers of materialquilt-stitched together and placed adjacent in parallel overlappingarrangement with one of the support surfaces of the innerspring; and anupholstery cover about the innerspring and the quilted internal pillow.28. A mattress pillowtop having an internal mattress pillow encapsulatedwithin, the internal mattress pillow having at least two layers ofmaterial which are in planar contact, with a quilt stitch pattern in amajor expanse of the layers, stitches of the quilt stitch patternextending through the layers to hold the layers together and to maintainalignment of the layers.
 29. The pillowtop of claim 28 wherein thequilted internal pillow comprises three layers, and wherein stitches ofthe quilt stitch pattern extend through all three layers.
 30. Thepillowtop of claim 28 wherein the layers of material of the internalquilted pillow are foam material.
 31. The pillowtop of claim 28 whereinthe layers of the internal quilted pillow are generally planar.
 32. Thepillowtop of claim 28 wherein at least one of the layers of the internalquilted pillow has a contoured surface.
 33. The pillowtop of claim 28further comprising a second mattress pillowtop positioned opposite tothe first mattress pillowtop and a second quilted internal pillowtopwhich is encapsulated within the second mattress pillowtop.